STR-4100 Dok-Lok Vehicle Restraint Owners Manual

Transcription

1 STR-4100 Dok-Lok Vehicle Restraint Owners Manual part of the SMOOTH TRANSITION DOK SYSTEM TM MADE IN U.S.A. This Manual Covers Restraints Built After Serial Numbers: 09GE and up PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO DECEMBER 2010

2 TABLE OF CONTENTS INTRODUCTION SAFETY WARNINGS OWNERS RESPONSIBILITY DEFINITION AND FUNCTION FEATURES OPERATING PROCEDURE MAINTENANCE TROUBLESHOOTING COMPONENT TESTING HORN OVERRIDE CODE VALVE BLOCK ASSEMBLIES ELECTRICAL SCHEMATIC - STAND ALONE POWER UNIT ELECTRICAL SCHEMATIC - COMBINATION POWER UNIT HYDRAULIC SCHEMATIC - STAND ALONE POWER UNIT HYDRAULIC SCHEMATIC - COMBINATION POWER UNIT REPLACEMENT PARTS WARRANTY BACK COVER INTRODUCTION Read and understand this manual before attempting to install or operate any DOK-LOK vehicle restraint. For best results, have this product serviced by your authorized RITE-HITE representative. The STR-4100 DOK-LOK vehicle restraint by RITE-HITE is intended to provide a safer workplace for workers in shipping and receiving dock areas. The STR-4100 DOK-LOK vehicle restraint is a hydraulic restraint device that, when properly installed and operated, retains a secure connection between the truck and dock. Signal lights and signs provide instructions to the truck driver and DOK-LOK vehicle restraint operator that a safe condition exists. The DOK-LOK vehicle restraint is operated by pressing push buttons on an inside control panel. PRODUCT SPECIFIC WARRANTY RITE-HITE warrants the STR-4100 DOK-LOK vehicle restraint for five-years parts and labor from date of shipment in accordance with Rite-Hite's Standard Warranty Policy. NOTICE TO USER Your local RITE-HITE representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative or the RITE-HITE Corporation at The RITE-HITE products in this manual are covered by one or more of the following U.S. patents: 5,271,183; 5,323,503; 5,546,623; 5,553,987; 5,582,498; 5,664,930; 5,702,223; 5,762,459 (RE: 37,570); 5,882,167; 6,065,172; 6,070,283; 6,085,375; 6,092,970; 6,106,212; 6,116,839; 6,190,109; 6,220,809; 6,276,016; 6,311,352; 6,318,947; 6,322,310; 6,360,394; 6,368,043; 6,431,819; 6,488,464; 6,499,169; 6,502,268; 6,505,713; 6,524,053; 6,634,049; 6,654,976; 6,726,432; 6,773,221; 6,832,403; 6,880,301; 6,892,411; 7,032,267; 7,062,814; 7,134,159; 7,213,285; 7,216,391; 7,363,670; 7,380,305; 7,503,089; 7,553,431; 7,578,097; 7,681,271 and pending U.S and foreign patent applications. RITE-HITE, LEVEL-RITE, THINMAN TM, SAFE-T-LIP, HYDRACHEK, WHEEL-LOK TM, DOK-LOK, DUAL-DOK, SAFE-T-STRUT TM, DOK-COMMANDER, JUMBO TM, HYDRA-RITE TM, SAFE-T-GATE, and SMOOTH TRANSITION DOK SYSTEM TM, are trademarks of RITE-HITE Corporation. 2 Pub. No December 2010

3 SAFETY WARNINGS When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. FIGURE 1 - LOCKOUT/TAGOUT LOCKOUT/TAGOUT PROCEDURES The Occupational Safety and Health Administration requires that, in addition to posting safety warnings and barricading the work area, the power supply has been locked in the OFF position or disconnected. It is mandatory that an approved lockout device is utilized. An example of a lockout device is illustrated. The proper lockout procedure requires that the person responsible for the repairs is the only person who has the ability to remove the lockout device. In addition to the lockout device, it is also a requirement to tag the power control in a manner that will clearly note that repairs are under way and state who is responsible for the lockout condition. Tagout devices have to be constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or become unreadable. RITE-HITE Corporation does not recommend any particular lockout device, but recommends the utilization of an OSHA approved device (refer to OSHA regulation ). RITE-HITE Corporation also recommends the review and implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These regulations are available through OSHA publication This is the highest level statement. Failure to follow the listed instructions will most likely result in severe injury or death. The statements used with this level of warning deal with a safe operating procedure. If the procedure is ignored, the possibility of personal injury may exist. This is a statement of serious hazard. Failure to follow the listed instructions could place the individual at risk of serious injury or death. IMPORTANT is used to draw attention to a procedure that needs to be followed to prevent machine or property damage. Pub. No December

4 OWNER RESPONSIBILITY 1. The owner should recognize the inherent danger of the interface between dock and transport vehicle. The owner should, therefore, train and instruct operators in the safe use of dock equipment in accordance with the information provided below. The manufacturer shall publish, provide to the initial purchaser, and make the following information readily available to owners: Installation instructions Recommended initial and periodic inspections procedures Maintenance procedures Operating instructions Descriptions or specifications for replaceable or repairable parts Tables identifying the grade (slope) for all variations of length or configuration of the dock equipment, and Information identifying the maximum uncontrolled drop encountered upon sudden removal of support while within the working range of the equipment. It shall be the responsibility of the owner to verify that the material listed in this section has been received and that it is made available for the instruction and training of presonnel entrusted with the use or maintenance of the dock equipment. 2. When a transport vehicle is parked at a loading dock, it is important that the vehicle is relatively perpendicular to the dock face and in close contact with at least one of the dock bumpers. 3. Nameplates, cautions, instructions, and posted warnings shall not be obscured from the view of operating or maintenance personnel for whom such warnings are intended. 4. Manufacturer s recommended periodic maintenance and inspection procedures in effect at date of shipment shall be followed, and written records of the performance of these procedures should be kept. 5. As with any piece of machinery, dock equipment requires routine maintenance, lubrication, and adjustments. Your local RITE-HITE representative offers owners the option of a Planned Maintenance Program (P.M.P.). As part of this service, your local RITE-HITE representative will do all routine maintenance, lubrication, and adjustments. 6. Dock equipment that is structurally damaged shall be removed from service, inspected by a manufacturer s authorized representative, and repaired as needed before being placed back in service. 7. The manufacturer shall make available replacement nameplates, caution/instruction labels, and operating/maintenance manuals upon request of the owner. The owner shall see that all nameplates, caution/instruction markings or labels are in place and legible, and that the appropriate operating/maintenance manuals are provided to users. 8. Modifications or alterations of dock equipment shall be made only with written permission of the original manufacturer. These changes shall also satisfy all safety recommendations of the original equipment manufacturer for the particular application of the dock equipment. 9. In order to be entitled to the benefits of the standard product warranty, the dock equipment must have been properly installed, maintained and operated within its rated capacities and/or specific design parameters, and not otherwise abused. 10. It is recommended that trailers equipped with air ride suspensions should remove the air from the suspension to minimize trailer bed drop, prior to loading or unloading. 11. When industrial trucks are driven on and off transport vehicles during the loading and unloading operation, the brakes on the transport vehicle shall be applied and wheel chocks or a positive restraining device shall be engaged. 12. In selecting dock equipment, it is important to consider not only present requirements but also future plans or adverse environments. 4 Pub. No December 2010

5 The STR-4100 DOK-LOK vehicle restraint is a hydraulic, self-aligning restraint device used to secure trucks and semi-trailers with an intact Rear Impact Guard (R.I.G.) to the face of a loading dock. In addition this device, when engaged, limits the vertical motion of the trailer when loading and/or unloading. This is achieved by securing the R.I.G. with a hydraulically positioned steel hook, while support cylinders extend under the carriage to limit vertical motion. This prevents forward movement of the truck/trailer that may create an unsafe void between the face of the dock and the rear end of the truck/trailer as a forklift travels from the loading dock onto the trailer; or to create an obstruction noticeable to the truck driver, should the driver accidentally try to pull the truck/trailer away while it is being serviced. The proper or improper activation of the hook and support function are monitored by: VISUAL CONTROL One set of flashing green or red lights located at the inside of the building for the forklift operator, and one set located outside of the building for the truck driver. In addition to the lights, there are three instruction signs. AUDIO CONTROL A horn will sound at the inside of the building, warning the forklift operator if there is not R.I.G. present, or if the engagement is improper. In this case, the trailer must be secured by other means (wheel chokes, etc.) prior to servicing trailer. RITE-HITE STR-4100 DOK-LOK Owner s Manual DEFINITION AND FUNCTION The normal mode of the hook is in the lower STORED position, with support cylinders retracted showing a flashing red light (trailer not secured) at the inside of the building and a flashing green light (trailer free to move to or away from the loading dock) at the outside of the building. Once the trailer is parked, the dock attendant will depress the Lock button. This will raise the hook to engage the R.I.G. and simultaneously extend the support cylinders to support the carriage. As soon as the R.I.G. is properly locked with carriage supported, there will be a simultaneous light change - the inside will change from red to green flashing (trailer secured and supported) and the outside will change from green to red flashing (do not move trailer). After the service is complete, the dock attendant will have to depress the Unlock button which then will return the hook and support cylinders to their STORED position. A proper hook engagement is achieved when the hook raises unobstructed to fully trap the horizontal cross member of the R.I.G. Assembly. An improper hook engagement is if the horizontal cross member of the R.I.G. is missing, obstructed or it is bent or located so far toward the rear axle of the trailer that it will prevent the free passage of the hook. At this point, the trailer must be secured by other means (example: wheel chocks) in order to become serviceable. Prerequisite for proper barrier engagement is that the trailer is parked firmly against a 4" (trade standard) thick dock bumper. The activation/deactivation is solely controlled from inside of the building by momentarily depressing either the Lock (raise) button or the Unlock (lower) button. The support cylinders will not be engaged without proper hook engagement. If trailer can not be secured, normal vertical motion of the trailer is to be expected. Pub. No December

6 FEATURES Refer to Figure 2, page 7 for the locations of the following features: R.I.G. Acronym used for the Federally mandated rear impact guard located on the rear of over the road trailers to prevent accidental underride by automobiles. ROLLER TRACK ASSEMBLY Mounted to the loading dock wall to guide the carriage assembly in a vertical plane and transmit the creep or pull out force from a trailer to the loading dock wall. CARRIAGE ROLLER ASSEMBLY Comprised of a steel roller housing, a pre-lubricated bearing to allow easy movement of the carriage assembly. CARRIAGE RETURN SPRINGS AND TUBES Bias the carriage assembly to its upward stored position and to maintain contact with the R.I.G. while servicing a trailer. CARRIAGE ASSEMBLY SLOPE EXTENSION Allows trailers with lower R.I.G. s to be serviced by the DOK-LOK vehicle restraint. HOOK Entraps R.I.G. to prevent trailer from rolling/creeping away from the dock. HOOK CYLINDER Provides means of moving the hook between its stored and active positions. SUPPORT CYLINDERS Provides a means to support the underside of the carriage, thus supporting the rear end of trailer. SENSING SWITCHES, CONTROL BOX, OUTSIDE LIGHT BOX AND SIGNAGE Combination of these components is used to control the STR-4100 DOK-LOK vehicle restraint and provide audio/visual communications to the dock attendant and trailer driver. CARRIAGE ASSEMBLY Sloped front provides self-positioning by the R.I.G. and restrains the trailer once the hook has been activated by the dock attendant. 6 Pub. No December 2010

7 outside signs inside sign light box control box hook cylinder hook carriage assembly power unit sensing switches carriage roller assembly support cylinders return springs and tubes auxillary manifold slope extension support switch roller track assembly base plate assembly FIGURE 2 - STR-4100 DOK-LOK VEHICLE RESTRAINT FEATURES Pub. No December

8 OPERATING PROCEDURES Before loading or unloading a vehicle at your loading dock while using a DOK-LOK vehicle restraint, always visually inspect to be sure that the barrier blocks the R.I.G. assembly. If a condition occurs that cannot be remedied by backing the trailer firmly against the dock bumpers, secure the trailer by other means. Be sure that the area around the R.I.G. assembly is free of plates or other obstructions. Always operate the DOK-LOK vehicle restraint from the top of the dock. Inspect all restraint lights daily to make certain they work properly. Perform maintenance on restraints in accordance with Maintenance on page 12 of this manual. DOK-LOK vehicle restraints should be operated only by authorized personnel who have read and understand the Owner s Manual. Call your local representative or RITE-HITE at (800) with any questions. FAILURE TO FOLLOW THESE PROCEDURES COULD ALLOW UNEXPECTED TRAILER / LOADING DOCK SEPERATION RESULTING IN DEATH OR SERIOUS INJURY! HANDS OFF Power Moving Components Serious Injury Could Occur Stored Position / Restraint UNLOCKED NO STEP Barrier is in the STORED position. Inside light is flashing red alerting forklift operator unsafe condition exists. Outside light is flashing green alerting truck driver it is safe to back in. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 3 - STORED POSITION 8 Pub. No December 2010

9 Restraint Locking, LOCK Button Pressed Trailer has backed into loading dock and is parked firmly against dock bumpers. Hook rotates from stored position to entrap the R.I.G. while the support cylinders extend to support the carriage. Inside light is steady red alerting the operator that an unsafe condition exists while hook and support cylinders are in transit. Outside light is flashing red alerting truck driver not to move. If trailer can not be restrained due to a lift gate or other obstruction that could become damaged, go to OVERRIDE state. If horn sounds, go to FAULT state, otherwise go to Restraint LOCKED. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 4 - RESTRAINT LOCKING Restraint LOCKED Once the R.I.G. is entrapped by the hook and the carriage is supported by support cylinders, a LOCKED condition exists. Inside light is flashing green alerting the forklift operator a safe condition exists. Outside light is flashing red alerting truck driver not to move. If during loading/unloading the inside light turns red and the horn sounds, press LOCK button to secure the R.I.G. Visually inspect to ensure that the DOK-LOK barrier obstructs the R.I.G. of the trailer being serviced before operating the dock leveler. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 5 - RESTRAINT LOCKED Pub. No December

10 Restraint UNLOCKING, UNLOCK Button Pressed Hook travels from the LOCKED position to the STORED position while the support cylinders retract. Inside light is steady red alerting the operator that an unsafe condition exists while hook and support cylinders are in transit. Outside light is flashing red alerting truck driver not to move. If horn sounds go to FAULT state, otherwise go to STORED. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 6 - RESTRAINT UNLOCKING FAULT State From LOCKING State Hook cannot entrap the R.I.G. This could be due to a R.I.G. that is located too far from rear of trailer, bent, obstructed or missing. Inside light is flashing red and horn is pulsing, alerting the forklift operator that the trailer is not locked. Outside light is flashing red alerting the truck driver not to move. The unit will store itself. If the trailer is parked firmly against the dock bumpers go to HORN OVERRIDE state. If not, press UNLOCK to clear the fault, have trailer back up and repeat Restraint LOCKING. FAULT State From UNLOCKING State Hook cannot rotate to the STORED position. The hook could be caught on the R.I.G. or another part of the trailer. Inside light is flashing red and horn is pulsing, alerting the forklift operator that the trailer is not locked. Outside light is flashing red alerting the truck driver not to move. Make sure trailer is parked firmly against the dock bumpers. If not, press LOCK to entrap R.I.G., have trailer back up and repeat Restraint UNLOCKING. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED 1 2 LOCK HORN GREEN 3 HORN OVERRIDE UNLOCK Inside Lights Outside Lights FIGURE 7 - FAULT STATE 10 Pub. No December 2010

11 HORN OVERRIDE State, HORN OVERRIDE Code Entered after Securing Trailer by Alternate Means An alternate means of securing the truck must be used if the hook can not capture the R.I.G. (i.e. wheel chocks). Inside lights are flashing red and green alerting the forklift operator the trailer is secured by other means. Outside light is flashing red alerting the truck driver not to move. To return to STORED, enter the HORN OVERRIDE CODE followed by the UNLOCK button. The support cylinders will not be engaged in HORN OVERRIDE STATE, vertical motion of the trailer is to be expected. NOTE: The unit will continue to store itself (approx. 20 seconds) after the horn has been silenced from the FAULT STATE. RESTRAINT POSITION CONTROL BOX STATUS OUTSIDE LIGHT STATUS RED GREEN RED HORN OVERRIDE LOCK UNLOCK GREEN Inside Lights Outside Lights FIGURE 8 - HORN OVERRIDE STATE Pub. No December

12 MAINTENANCE When working with electrical or electronic controls, make sure that the power source has been locked out and tagged according to OSHA regulations and approved local electrical codes. Post safety warnings and barricade work area, at dock level and at ground level, to prevent unauthorized use of the dock position. NOTE: Your local RITE-HITE representative provides a Planned Maintenance Program (P.M.P.) which can be fitted to your specific operation. Call your local representative. DAILY 1. Remove debris around DOK-LOK vehicle restraint. 2. Verify inside and outside lights are working. 3. Replace damaged or missing light bulbs and lenses. 4. Repair, remount, or replace outside and inside signs as required. 5. Inspect dock bumpers. Four inches (4") of protection is required. Worn, torn, loose or missing bumpers must be replaced. A safe work place requires all lights and the horn to be working properly. DO NOT use DOK- LOK vehicle restraint if parts are broken or missing. When lifting unit use a proper lifting device (ex. crane, jack). Lifting by hand may cause back injury. Maintenance may be required more frequently at loading docks exposed to harsh environments (extreme climates, corrosive chemicals, frequency of usage, etc.). Consult RITE-HITE if these conditions exist for accelerated maintenance requirements. NOTE: If a leveler is installed at the STR-4100 DOK-LOK vehicle restraint location, it may be necessary to raise the leveler before performing maintenance. Raise the leveler, insert and secure the SAFE-T-STRUT, and LOCKOUT/ TAGOUT the power source. 180 DAYS 1. Perform all Daily maintenance. 2. Grease rollers at fittings located on the top and bottom axle. Grease hoot at fitting. See figure 9. Use Mobilith SHC220 No. 2 grease (or equivalent temperature range lithium based grease). Seven (7) to eight (8) pumps should be used for first 180 day maintenance. Two (2) or three (3) pumps at subsequent 180 Day maintenance intervals. NOTE: Items that use SAE 30 weight oil lubricant only require lubrication every 360 Days. 3. Check that all concrete anchor bolts are torqued to 100 ft-lbs. 4. Inspect hydraulic hoses and power unit for signs of leakage. Check oil fluid level, and fill with appropriate fluid as needed. 5. Inspect pit junction and light box. They should be rigidly mounted. If loose or damaged, inspect all wires and wire connections. 6. Inspect switch wires from DOK-LOK vehicle restraint to junction box. Look for kinks, crushed areas, etc. 12 Pub. No December 2010

13 7. Inspect all conduit boxes, control boxes and electrical connections for damage. Repair or replace if worn or damaged. NOTE: If control box has evidence of condensation. a. Inspect conduit. Conduit should be routed to enter through the bottom or side of the enclosure. A drip leg may be needed if the conduit is filling with water. b. Inspect the seal on the cover of the enclosure. The seal should be securely adhered to the cover with no signs of peeling or bubbling. Repair or replace if worn or damaged. c. For non-metalic enclosures, breather vent part number may be installed. The vent is NEMA 4X and will not change the enviromental rating of the control box. 8. Perform operational test after all maintenance repairs and adjustments are complete. 360 DAYS MAINTENANCE CONT. 1. Perform daily and 180 days maintenance. 2. Check and tighten control box mounting hardware. SAE 30 Weight Oil Grease Dry Spray Lubricate NOTES: a. Use Mobilith SHC220 No. 2 grease (or equivalent temperature range lithium based grease) b. Use a dry spray lubricate in slots and on the outside of lower spring tubes as shown. FIGURE 9 - LUBRICATION Pub. No December

14 TROUBLESHOOTING GENERAL DIAGNOSTIC INFORMATION Problem Probable Cause Solution 1. DOK-LOK vehicle restraint hook does a. Power source malfunction. a. Check power source including building not raise and lights do not flash. circuit breaker, 1A and 20A fuse on the power module. b. Power module failure. b. Verify the appropriate motor output LED (M1), and SOL LED is lit when the LOCK button or UNLOCK button is pressed. c. Incorrect wiring. c. Verify wiring per Electrical Schematic. 2. DOK-LOK vehicle restraint lights are a. Hook needs to be lubicated. a. Lubricate hook shaft. flashing, but hook does not raise/ b. Severed Hose. b. Replace damaged hose as required. lower. c. Power module failure. c. Verify the appropriate LED is lit when the LOCK button or UNLOCK button is pressed. d. No push button inputs. d. Check for defective push button board or ribbon cable. e. Hook Cylinder defective. e. Disconnect cylinder and check extension / retraction without hook attached. f. Incorrect wiring. f. Verify wiring per Electrical Schematic. 3. DOK-LOK vehicle restraint is a. Hook Cylinder defective. a. Disconnect cylinder and check operational but hook drops causing extension / retraction without hook lights to change and/or horn to sound attached. while trailer is being serviced. 4. DOK-LOK vehicle restraint hook is a. Bulbs burnt out, loose or missing. a. Check all bulbs and replace as operational but all lights are out. required. b. Bad Light Fuse b. Replace as required. c. Damaged CPU module. c. If the ISG and OSR LEDs are not flashing while in the locked position or the ISR and OSG LEDs are not flashing while in the UNLOCKED position, replace the CPU module as required. d. Incorrect wiring. d. Verify wiring per Electrical Schematic. 5. DOK-LOK vehicle restraint inside red a. Controls are in neutral state. a. Contact your local representative or light and horn are pulsing. Outside red RITE-HITE. light is flashing. All buttons do not function. 6. DOK-LOK vehicle restraint horn does a. Horn is defective. a. Power horn using 12V DC power. If not sound, but lights and hook are horn does not sound, replace as operational. required. 7. DOK-LOK vehicle restraint hook is in a. Incorrect wiring a. Verify wiring of SW1 and SW2 at the stored position with an inside green light. control box and outside junction box. 8. DOK-LOK vehicle restraint carriage a. Carriage binding in track. a. Check to see if roller track plate is clean does not return to a full up position and rollers are clean, free of debris and lubricated. Use only approved grease to lubricate rollers. b. Damaged roller track plate. b. Verify that the roller track plate is straight and not damaged. c. Broken or weak springs c. Replace as required. d. Improperly shimmed Base Plate d. Shim and adjust as required. 14 Pub. No December 2010

15 COMPONENT TESTING Mag. Res. Limit Switch Test Procedure (SW1 & SW2) 1. Set multimeter to RX1 scale for Continuity Test. 2. Attach multimeter leads to white and black wires of mag. res. switch connector. You should have: no magnet present no meter reading. magent present a Full Scale meter reading. Mech. Limit Switch Test Procedure (SW3) 1. Set multimeter to RX1 scale for Continuity Test. white black sensing switch magnet FIGURE 10 - MAGNETIC RESISTANT LIMIT SWITCH (SW1 & SW2) 2. Attach multimeter leads to white and black wires of limit switch connector. You should have: plunger released no meter reading. plunger depressed a Full Scale meter reading. NOTE: The green (ground) wire of the limit switch does not have to be tested. A continuity test lamp may be used instead of a multimeter. fixed guide limit switch body plunger w/roller mounting bolt holes wire harness NOTE: Limit Switch 1 (SW1) and Limit Switch 3 (SW3) are wired in series into the SW1 input on the CPU module. green black white red (not used) Limit Switch and Hook Position Chart Hook Position Limit Switch 1 Lock (SW1) (Mag. Res. Switch) Limit Switch 2 Unlock (SW2) (Mag. Res. Switch) FIGURE 11 - MECHANICAL LIMIT SWITCH (SW3) Limit Switch 3 Support (SW3) (Mech. Switch) Inside Light Outside Light Horn 1. Stored Off On Open Red Green Off 2. No Hook (No Support) Off Off Open Red Red On 3. Hooked/Support On Off Closed Green Red Off 4. No Hook (Support On) Off Off Closed Red Red On Pub. No December

16 PB1,2&3 RITE-HITE STR-4100 DOK-LOK Owner s Manual COMPONENT TESTING CONT. Vehicle Restraint Motor Test Procedure hydraulic power unit 1. SHORTED: Set multimeter to ohms. a. Take readings between leads M1 to ground/motor casing and COM to ground/motor casing. b. Reading should be Infinite (0) ohms (no needle movement). c. Any reading indicates bad motor windings. 2. MECHANICAL BINDING: Motor hums. Motor leads show continuity between all windings. Shaft does not move. multimeter G COM M1 FIGURE 12 - MOTOR TEST Restraint State LED Inputs LED Outputs SW1 SW2 LOCK PB UNLOCK PB Stored (Unlocked) F T P F F P F F F F F * T Locking F F M - - T F P F F T T T F * T Locked T F F P P F F F T F T * T Storing (Unlocking) F F - M - T F P F F T F T F * T Fault F F P F P F P F F F F * F Horn Silence?? - - M P P P F F F F F T * T SW1 = MAG RES (SW1- LOCK) + MECH (SW3 - SUPPORT) ISR = Inside Red Light SW2 = MAG RES (SW2 - UNLOCK) ISG = Inside Green Light LOCK PB = Lock Push Button OSR = Outside Red Light UNLOCK PB = Unlock Push Button OSG = Outside Green Light PB1, 2, & 3 = Horn Silence Code Push Buttons HORN = Alarm Horn M1 = Power Unit Run SOL1 = Hook / Support Solenoid SOL2 = Leveler Block SOL2 + SOL3 (Combo Only) CR1 = Green Light Interlock Output INPUT FAULT = SW1/SW2 did not sense a safe CR2 = Unidox Output LOCK/UNLOCK CR3 = Security System Output ISR ISG OSR OSG HORN M1 SOL1 CR1 CR2 CR3 T = Steady ON D = Double Pulse F = OFF P = Pulsing/Flashing * = TRUE when Unidox is enabled? = Varies depending on operation M = Lights when button is pressed FIGURE 13 - LED STATUS CHART SOL2 (Combo Only) 16 Pub. No December 2010

17 SETTING HORN OVERRIDE CODE 1. Press and hold DIAGNOSTIC button until horn chirps (approximately three seconds). 2. Enter the factory preset HORN OVERRIDE code: Enter the new HORN OVERRIDE code. The code can be one to four numbers in length. 4. Once the new code has been entered, press the LOCK button. 5. Controls reset with new HORN OVERRIDE code enabled. If no buttons are pressed within a five minute period, the controls will automatically retain the previous code. To exit the HORN OVERRIDE code set mode at any time, press the DIAGNOSTIC button. If code has been forgotten, follow the above procedures and enter a new code. RITE-HITE STR-4100 DOK-LOK Owner s Manual HORN OVERRIDE CODE Diagnostic Button FIGURE 14 - DIAGNOSTIC / FILL MODE BUTTON Pub. No December

18 HOSE ROUTING NOTE: DO NOT Overtighten Hose Fittings! From P Port On Valve Block To P Port On Power Unit NOTE: Stand Alone Power Hoses Are Not Trimable From L Port On Valve Block To L Port On Power Unit FIGURE 15 - HOSE ROUTING - STAND ALONE POWER UNIT NOTE: DO NOT Overtighten Hose Fittings! WKC (SOL3) RAMP DIVERT Solenoid WKX (SOL1) RAISE Solenoid WKV (SOL 2) LIP BLOCK Solenoid From P Port On Restraint Valve Block To RP Port On Combination Power Unit Valve Block NOTE: Remote Power Hoses Are Trimable, See Installation Manual for Trimming Instructions FIGURE 16 - HOSE ROUTING - COMBINATION POWER UNIT From L Port On Restraint Valve Block To LP Port On Combination Power Unit Valve Block 18 Pub. No December 2010

19 VALVE BLOCK ASSEMBIES NOTE: Mounted On STR-4100 Carriage. HL Port - Hook Cylinder Retract HR Port - Hook Cylinder Extend L Port To Power Unit or Combo Valve Block P Port To Power Unit or Combo Valve Block MR Port - Raise Support Cylinder (Left) ML Port - Lower Support Cylinder (Left) ML Port - Lower Support Cylinder (Right) MR Port - Raise Support Cylinder (Right) FIGURE 17 - AUXILLARY MANIFOLD ASSEMBLY NOTE: Located Adjacent To Leveler Power Unit. Only On Combination Power Units. WKV (SOL 2) LIP BLOCK Solenoid WKC (SOL 3) RAMP DIVERT Solenoid WKV (SOL 2) LIP BLOCK Solenoid LP Lower Port to STR4 LO Leveler Lip Out Port WKC (SOL 3) RAMP DIVERT Solenoid RP Raise Port to STR4 WKX (SOL 1) RAISE Solenoid NOTE: This Face Towards Front Of Pit T Return to Tank Port FIGURE 18 - COMBINATION POWER UNIT VALVE BLOCK ASSEMBLY RO Leveler Ramp Out Port Pub. No December

20 ELECTRICAL SCHEMATIC - STAND ALONE POWER UNIT NOTES: 1. Power Supply Disconnect Or Protection Device Supplied At Installation. (By Others) 2. All Incoming Wiring (L1, L2) To Be Minimum #12GA. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Voltage. (See Chart) 3. All Other Wiring To Be #16GA. Minimum 90 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 4. Class 1 Control Circuit. 5. Use Insulated 1/4 Female Spade Connectors. 6. Installation Per Local Electrical Codes. Refer All Installation And Service To Qualified Personnel. See Chart For Wire Size To Customer Power Supply 120v, 1PH, LY, 60Hz, 20 Amp. 30 Amp. Rated Fused Disconnect With 20 Amp. Dual Element Time Delay Fusing. (Supplied By Others) (G) (L1) (L2) SCOM L1 L2 MCOM M1 MCom Motor - 1 H.P. 120v. 1Ph. 50/60 Hz. 9F.L.A. M1 M (1) SCom ISA2 PUSH BUTTON BOARD R LOCK UNLOCK G R G HS #1 1 HS #2 HS # Orange ISR 12 VDC,.54A Green ISG 12 VDC,.54A Power Module Diagnostic / Fill Mode Button + 12VDC + 12VDC Ambr Lt Cntrl OSR Sense OSG Sense GND GND HS #3 HS #2 HS #1 Lock Unlock CPU module Red Red Yellow White/Orange White/Green Black Black Violet Brown Gray Blue White ISA PB3 PB2 PB1 LOCK UNLOCK OSG ISR OSR ISG HORN SW2 SW1 +V1 SW1+ SW1- +V2 SW2+ SW2-250v. 1A Fast Blow CR4 CR5 SOL2 OSPWR OSG OSR SOL1 M1 CR3 CR2 CR1 250v. 20A Slow Blow SOL1 SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (2) Sol1 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock RAISE SOL1 (BLK) (WHT) 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF ON H Horn Red +12V White/Black Horn - 12 VDC, 0.03A White/Red Horn + (SW1+) (SW2+) mech./ FA interconnect hydraulic interconnect raise photoeye interconnect white black Support Limit Switch (SW3) (WH) (BLK) N.O. (SW1-) (SW1-) white black (42) (41) G Outside Light Power Outside Light Green 12VDC, 2.1A Safe Hook LOCKED Sensor Switch (SW1) Hook UNLOCKED Sensor Switch (SW2) (40) R Outside Light Red 12VDC, 2.1A LEGEND WIRE SIZE REQUIREMENTS lable LED lamp Wire Run Length denotes field wiring Wire Gauge Size 12GA 10GA 8GA NOTE: Use included female spade connectors for installation. FIGURE 19 - ELECTRICAL SCHEMATIC - STAND ALONE POWER UNIT 20 Pub. No December 2010

21 ELECTRICAL SCHEMATIC - COMBO POWER UNIT NOTES: 1. Power Supply Disconnect Or Protection Device Supplied At Installation. (By Others) 2. All Incoming Wiring (L1, L2) To Be Minimum #12GA. 60/75 Deg. C Copper Wire Only, Insulated Sufficiently For Incoming Voltage. (See Chart) 3. All Other Wiring To Be #16GA. Minimum 90 Deg. C Copper Wire, Insulated Sufficiently For Incoming Voltage. 4. Class 1 Control Circuit. 5. Use Insulated 1/4 Female Spade Connectors. 6. Installation Per Local Electrical Codes. Refer All Installation And Service To Qualified Personnel. NOTE: Attach Leads From Dok-Lok Power To The LOWER Button When Module Combining With A VHL Leveler. ISA2 10FU1 1.0A 250V DUAL ELM TD PUSH BUTTON BOARD R LOCK UNLOCK G R G "RAISE" Leveler Control Box HS #1 1 HS #2 HS #3 LEVELER CONTACTOR (A1) (A2) 12 1 Orange ISR 12 VDC,.54A Green ISG 12 VDC,.54A Diagnostic / Fill Mode Button + 12VDC + 12VDC Ambr Lt Cntrl OSR Sense OSG Sense GND GND HS #3 HS #2 HS #1 Lock Unlock H3 (BK) H5A (RD) CPU module Red Red Yellow White/Orange White/Green Black Black Violet Brown Gray Blue White PB3 PB2 PB1 LOCK UNLOCK ISA ISR ISG OSG OSR To Customer Power Supply 120v, 1PH, 60Hz, 15 Amp. Fused Disconnect With 1 Amp. Dual Element Time Delay Fusing (Supplied By Others) (G) HORN SW2 SW1 +V1 SW1+ SW1- +V2 SW2+ SW2- SCOM 250v. 1A Fast Blow CR4 CR5 SOL2 L1 L2 MCOM M1 OSPWR OSG OSR (L1) SOL1 M1 (L2) CR3 CR2 CR1 250v. 20A Slow Blow SOL1 NOTE: Lip Block Solenoid Not Used When Combining Dok-Lok With A VHL Leveler. (1) SCom RAISE SOL1 (WKX) (2) Sol1 (BLK) (WHT) SOL2 CR3 CR2 CR1 AUX1 AUX2 AUX3 (3) Sol2 (8) Sol3 CR3_A CR3_B CR2_A CR2_B CR1_A CR1_B AUX1+ AUX1- AUX2+ AUX2- AUX3+ AUX3- leveler/ overhead door stored interlock 120 VAC, 0.23 AMPS LIP BLOCK SOL2 (WKV) (BLK) (WHT) 120 VAC, 0.23 AMPS RAMP DIVERT SOL3 (WKC) (BLK) (WHT) 120 VAC, 0.23 AMPS security system interface output unidox interconnect output green light interlock output Options module unidox interconnect selector switch OFF ON H Horn Red +12V White/Black Horn - 12 VDC, 0.03A White/Red Horn + (SW1+) (SW2+) mech./ FA interconnect hydraulic interconnect raise photoeye interconnect white black Support Limit Switch (SW3) (WH) (BLK) N.O. (SW1-) (SW1-) white black (42) (41) G Outside Light Power Outside Light Green 12VDC, 2.1A Safe Hook LOCKED Sensor Switch (SW1) Hook UNLOCKED Sensor Switch (SW2) (40) R Outside Light Red 12VDC, 2.1A LEGEND lable LED lamp denotes field wiring NOTE: Use included female spade connectors for installation. FIGURE 20 - ELECTRICAL SCHEMATIC - COMBINATION POWER UNIT Pub. No December

22 HYDRAULIC SCHEMATIC - STAND ALONE POWER UNIT HOOK CYLINDER 1.25 x 3 x.5 ROD HR (HOOK RAISE) #4SAE RV Relief Valve, 2000 PSI HL (HOOK LOWER) #4SAE ML (MAIN LOWER) #6SAE CV Check Valve PP Pilot To Open CV Check Valve L (LOWER) #6SAE ML (MAIN LOWER) #6SAE MAIN SUPPORT CYLINDER, LH 3.5 x 9 MR (MAIN RAISE) #6SAE NOTE: THIS HOSE IS A #4SAE HOSE. PCC Pilot To Close Check Valve P (PRESSURE) #6SAE MR (MAIN RAISE) #6SAE AUXILLARY MANIFOLD MOUNTED ON CARRIAGE MAIN SUPPORT CYLINDER, RH 3.5 x 9 #6SAE P (PRESSURE) RAISE (SOL1) L (LOWER) #6SAE HOLDING CHECK VALVE, 50PSI VMS ORIFICE, V 2POS 4WAY SOLENOID RAISE/LOWER SELECTOR SOLENOID IS POWERED DURING LOCKED AND LOCKING STATES. ADJUSTABLE SYSTEM RELIEF, 675 PSI MOTOR: M 120/1/60 RESERVOIR: 1 GALLON VERTICAL & HORIZONTAL MOUNT SCREEN AND MAGNET STAND ALONE POWER UNIT FIGURE 21 - HYDRAULIC SCHEMATIC - STAND ALONE POWER UNIT 22 Pub. No December 2010

23 HYDRAULIC SCHEMATIC - COMBO POWER UNIT HOOK CYLINDER 1.25 x 3 x.5 ROD HR (HOOK RAISE) #4SAE RV Relief Valve, 2000 PSI HL (HOOK LOWER) #4SAE ML (MAIN LOWER) #6SAE CV Check Valve PP Pilot To Open CV Check Valve L (LOWER) #6SAE ML (MAIN LOWER) #6SAE MAIN SUPPORT CYLINDER, LH 3.5 x 9 MR (MAIN RAISE) #6SAE NOTE: THIS HOSE IS A #4SAE HOSE. PCC Pilot To Close Check Valve P (PRESSURE) #6SAE MR (MAIN RAISE) #6SAE AUXILLARY MANIFOLD MOUNTED ON CARRIAGE MAIN SUPPORT CYLINDER, RH 3.5 x 9 RO (RAMP OUT) #6SAE PCC Pilot To Close Check Valve, 50 PSI RAMP DIVERT (SOL3) WKC RP #6SAE (RAISE PORT).020 Orifice CV Check Valve RAISE (SOL 1) WKX LP (LOWER PORT) #6SAE T (TANK) #6SAE LO (LIP OUT) #4SAE RV Relief Valve, 675 PSI LIP BLOCK (SOL2) WKV RI (RAMP IN) #6SAE LI (LIP IN) #4SAE FIGURE 22 - HYDRAULIC SCHEMATIC - COMBINATION POWER UNIT COMBINATION POWER UNIT VALVE BLOCK. LOCATED ADJACENT TO LEVELER POWER UNIT Pub. No December

24 OUTSIDE LIGHT BOX WIRING #40 Wire White Wire Red Wire #42 Wire Red Lamp Red Wire Green Lamp #41 Wire White Wire Light Box Cover FIGURE 23 - OUTSIDE LIGHT BOX WIRING 24 Pub. No December 2010

25 NOTES Pub. No December

26 CARRIAGE & TRACK REPLACEMENT PARTS NOTE: DECK OF CARRIAGE WELDMENT REMOVED FOR CLARITY Pub. No December 2010

27 CARRIAGE & TRACK ASSEMBLY PARTS LIST Item Qty Description Part Number 1 1 Base Plate Track Weldment Track Cover Weldment Inch Carriage Weldment Hook Weldment Nose Weldment Upper Spring Tube Compression Spring - W/ Mounting Height > Compression Spring - W/ Mounting Height > 23 and < Compression Spring - W/ Mounting Height > 21 and < Lower Spring Tube Support Cylinder Hook Cylinder Clevis Pin - Upper Spring Tube Clevis Pin - Nose Weldment Clevis Pin - Hook Weldment Mag. Res Switch Sensor Bracket Magnet High Energy Rubber - Lower Magnet High Energy Rubber - Upper Auxillary Manifold - Complete Patent Decal Carriage Roller Washer OD x ID Grease Fitting Flat Washer Washer OD x 1.25 ID Lock Washer Cotter Pin Cotter Pin Warning Decal Screw, #6-32 x.599 Pan SST Mag. Res. Switch Nut, #6-32 Nylock SST Cotter Pin,.125Dia. x 2L ZP Bolt, HEX UNC x.75 ZP Screw x 2.00 Cap SKT HEX Nut Nylock Bolt, #10-24 x.50 HEX GR5 ZP Split Lock Washer, # Limit Switch, Roller Plunger Screw, SHCS x 1L ZP Nut, HEX FLG ZP Hydraulic Elbow Fitting, 90 0 #6 SAE(M) #6 JIC(M) Decal, Serial Number/ Model Clevis Pin - Lower Spring Tube, 5.75 x Clevis Pin - Hook Cylinder Plug, Male #6 MORB Washer 1.265OD x Washer 1.5OD x 1.063IO Clevis Pin - Support Cylinder - Lower Pin Pub. No December

28 HYDRAULIC REPLACEMENT PARTS , 26, Item Qty Description Part Number 1 1 Hook Cylinder Hose Assembly - Hook Cylinder - HL (Hook Lower) Hose Assembly - Hook Cylinder - HR (Hook Raise) Hose Assembly - Left Side Support Cylinder - MR (Main Raise) Hydraulic Fitting - Support Cylinders & Power Unit Support Cylinders Hose Assembly - Left Side Support Cylinder - ML (Main Lower) Hydraulic Fitting Hydraulic Elbow Fitting System Relief Valve Hydraulic Fitting Auxillary Manifold - Complete Hose Assembly Solenoid Coil Hydraulic Valve - Solenoid Operated Hose Assembly - Right Side Support Cylinder - MR (Main Raise) Hose Assembly - Right Side Support Cylinder - ML (Main Lower) Hydraulic Plug Cotter Pin Washer 1.5OD x 1.063ID Clevis Pin - Support Cylinder - Lower Pin Clevis Pin - Hook Cylinder - Lower Pin Cotter Pin Stand-Alone Power Unit Assy Hydraulic Oil Tank Hydraulic Oil Tank 0-Ring/Seal Hydraulic Oil Tank Dipstick/Breather Cap Pub. No December 2010

29 HYDRAULIC REPLACEMENT PARTS COMBINATION POWER UNIT VALVE BLOCK PARTS NOTE: THIS FACE TOWARDS FRONT OF PIT Item Qty Description Part Number 1 1 Combination Valve Block Assembly Complete Solenoid Coil Hydraulic Valve - WKC - SOL Hydraulic Valve - WKX - SOL Hydraulic Valve - WKV - SOL Hydraulic Relief Valve Hydraulic Check Valve Hydraulic Check Valve Hirschmann Plug Rect. & Harn. Assy. (Not Shown) Pub. No December

30 ELECTRICAL REPLACEMENT PARTS M1 SOL1 SOL #14 ga. wire x 5 long with ring terminal existing black wire light base control box Pub. No December 2010

31 ELECTRICAL REPLACEMENT PARTS LIST Item Qty Description Part Number 1 1 Control box assembly, complete (Consult RITE-HITE for specific part) 103.xxx 2 1 Electrical schematic decal (Consult RITE-HITE for specific part) 108.xxx 3 2 Inside red LED bulbs Inside green LED bulbs Light bulb (#194 - Incandescent) Insulated female terminal 1/4, awg Fuse, 1amp 250volt fast blo Inside signal light, green assembly Inside signal light, green lens Inside signal light, red assembly Inside signal light, red lens Push button module, 5 button includes mounting hardware Combo Power module includes subplate & mounting hardware CPU module includes mounting hardware Options module, not included in STANDARD control box assembly Program configuration decal (Consult RITE-HITE for specific part) 107.xxx 15 1 Full Load Amp and Voltage Decal (Consult RITE-HITE for specific part) 110.xxx 16 1 Horn, 12VDC Wiring harness Grounding harness Screw, panhead (#10-32 x.250) Lock washer, internal tooth # Screw, round head #8-32 x 1.00 (red light only) Screw, round head #8-32 x Screw, round head #8-32 x.50 (green light only) Nut, hex (#8-32) Lock washer, external tooth # Washer, nylon 0.26 ID x 0.75 OD x 0.10 thk Bushing, nylon Common wire, light assembly Outside light box LED, complete Outside light box, complete (Incandescent) Outside light box cover LED, with lamps & lenses Outside light box cover, with lamps & lenses (Incandescent) Screw, round head #6-32 x 3/4" Long Outside red LED bulb Outside green LED bulb Light bulb (GE # Incandescent) Lamp socket assembly Outside light box, NEMA 3R, (without cover) Fuse, 20 amp 250v Fuse, 4 Amp Pub. No December

32 This Manual Covers Restraints Built After Serial Numbers: 05GD150001W and up part of the SMOOTH TRANSITION DOK SYSTEM TM PRINTED IN U.S.A. RITE-HITE PRINT SHOP PUBLICATION NO Copyright 2004, 2005, 2006 SEPTEMBER 2006 RITE-HITE STR-4100 DOK-LOK Owner s Manual MISC. PARTS Vehicle Restraint Owners Manual STR-4000 Dok-Lok 4 10 MADE IN U.S.A. Effective 9/ MISCELLANEOUS REPLACEMENT PARTS LIST Item Qty Description Part Number 1 1 Interior Warning sign Narrow sign (normal letters) Narrow sign (reverse letters) STR warning decal Cover decal - 5 button - STR Lockout/tagout warning decal STR-4100 Owner s manual (Publication No. 1244) Pub. No Pub. No December 2010

33 NOTES Pub. No December

34 NOTES 34 Pub. No December 2010

35 NOTES Pub. No December

36 RITE-HITE STANDARD WARRANTY RITE-HITE warrants that its products will be free from defects in design, materials, and workmanship for a period of 365 days from the date of shipment. All claims for breach of this warranty must be made within 30 days after the defect is or can, with reasonable care, be detected and in no event no more than 30 days after the warranty has expired. In order to be entitled to the benefits of this warranty, the products must have been properly installed, maintained, and operated within their rated capacities and/or specified design parameters, and not otherwise abused. Periodic lubrication and adjustment is the sole responsibility of the owner. This warranty is RITE-HITE s exclusive warranty. RITE-HITE EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS. Nonstandard warranties, if any, must be specified by RITE-HITE in writing. In the event of any defects covered by this warranty, RITE-HITE will remedy such defects by repairing or replacing any defective equipment or parts, bearing all the costs for parts, labor, and transportation. This shall be the exclusive remedy for all claims whether based on contract, negligence, or strict liability. LIMITATION OF LIABILITY RITE-HITE SHALL NOT IN ANY EVENT BE LIABLE FOR ANY LOSS OF USE OF ANY EQUIPMENT OR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, WHETHER FOR BREACH OF WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. National Sales & Service Office: RITE-HITE 8900 N. Arbon Drive P.O. Box Milwaukee, Wisconsin Phone: Representatives in all Major Cities